US6839606B2 - Horizontally structured manufacturing process modeling for fixtures and tooling - Google Patents

Abstract

Disclosed is a method of horizontally structured CAD/CAM manufacturing for fixtures and tooling comprising: selecting a contact area geometry; creating extracts from a master process model; generating a tooling model corresponding to the contact area geometry; virtual machining the tooling model to generate the fixtures and tooling; and generating machining instructions and drawings to create the fixtures and tooling; where the tooling model exhibits an associative relationship with the contact area geometry. Also disclosed is a manufactured part created by a method of horizontally structured CAD/CAM manufacturing for fixtures and tooling comprising: a contact area geometry selected from a master process model for tooling or fixture modeling; extracts created from the master process model; a tooling model corresponding to the contact area geometry including virtual machining the tooling model to generate the fixtures and tooling; where the fixtures and tooling are created by machining in accordance with a machining instruction; and the tooling model exhibits an associative relationship with the contact area geometry. Also disclosed is a storage medium encoded with a machine-readable computer program code for horizontally structured CAD/CAM manufacturing. The storage medium including instructions for causing a computer to implement the method of horizontally structured CAD/CAM modeling and manufacturing for fixtures and tooling. Additionally disclosed is a computer data signal for horizontally structured CAD/CAM manufacturing. The computer data signal comprising code configured to cause a processor to implement a method of horizontally structured CAD/CAM modeling and manufacturing for fixtures and tooling.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. provisional application No. 60/276,255, filed Mar. 14, 2001 the contents of which are incorporated by reference herein in their entirety.

BACKGROUND

This disclosure relates to Computer-Aided Design and Computer-Aided Manufacturing (CAD/CAM) methods. CAD/CAM software systems are long known in the computer art. Some utilize wire-and-frame methods of building models while others utilize form features. Typically, in the form feature method of building CAD/CAM models, physical features are added to the model in an associative relationship with whatever other feature they are immediately attached to. Unfortunately, then, the alteration or deletion of any one feature will result in the alteration or deletion of any other features attached to it. This makes altering or correcting complicated models extensive and time-consuming.

BRIEF SUMMARY

Disclosed is a method of horizontally structured CAD/CAM manufacturing for fixtures and tooling, comprising: selecting a contact area geometry for tooling or fixture modeling; creating extracts from a master process model; generating a tooling model corresponding to the contact area geometry; virtual machining the tooling model to generate the fixtures and tooling; and generating machining instructions and drawings to create the fixtures and tooling; where the tooling model exhibits an associative relationship with the contact area geometry.

Also disclosed is a manufactured part created by a method of horizontally structured CAD/CAM manufacturing for fixtures and tooling, comprising: a contact area geometry selected from a master process model for tooling or fixture modeling; extracts created from the master process model; a tooling model corresponding to the contact area geometry including virtual machining the tooling model to generate the fixtures and tooling; where the fixtures and tooling are created by machining in accordance with a machining instruction; and the tooling model exhibits an associative relationship with the contact area geometry.

Also disclosed is a storage medium encoded with a machine-readable computer program code for horizontally structured CAD/CAM manufacturing. The storage medium including instructions for causing a computer to implement the method of horizontally structured CAD/CAM modeling and manufacturing for fixtures and tooling.

Additionally disclosed is a computer data signal for horizontally structured CAD/CAM manufacturing. The computer data signal comprising code configured to cause a processor to implement a method of horizontally structured CAD/CAM modeling and manufacturing for fixtures and tooling.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic of the horizontal modeling method;

FIG. 2 is a magnified view of the relative 3-D coordinate system used inFIG. 1;

FIG. 3 is an example of the vertical modeling method;

FIG. 4 is a diagram depicting an alternative embodiment of the horizontal modeling method;

FIG. 5 is a schematic of the manufacturing process modeling method;

FIG. 6 depicts the virtual machining of the manufacturing process modeling method;

FIG. 7 shows a typical process sheet;

FIG. 8 is a schematic of the enhanced horizontally structured manufacturing process;

FIG. 9 is a diagram depicting the relationships among the elements of the manufacturing process model for the enhanced manufacturing process modeling;

FIG. 10 is a diagram depicting the relationships among the elements of the manufacturing process model with respect to the part link/unlink features;

FIG. 11 is a diagram depicting the relationships among the elements of the manufacturing process model for alternate operations;

FIG. 12 is a diagram depicting the relationships among the elements of the manufacturing process model for large-scale models;

FIG. 13 is a diagram depicting the relationships among the elements of the manufacturing process model for charted parts;

FIG. 14 is a diagram depicting concurrent product and process design;

FIG. 15 is a diagram depicting the virtual fixture/tooling manufacturing process modeling;

FIG. 16 is a diagram depicting the automated manufacturing process design modeling; and

FIG. 17 depicts an exemplary spread sheet as referenced in the automated manufacturing process design modeling disclosure.

DETAILED DESCRIPTION

Disclosed herein is a horizontal method of computer-aided design and computer aided manufacture (CAD/CAM) modeling that is superior over the modeling employing vertical methods. The disclosed embodiments permit alterations, additions, and deletions of individual features (e.g., holes, bosses, etc.) of a virtual part, wherein a change in any one feature is independent of the remaining features. The disclosed method may be implemented on any CAD/CAM software package that supports (a) reference planes or their Cartesian equivalents, (b) parametric modeling or its equivalent, and (c) feature modeling or its equivalents.

A “horizontal tree structure” is employed to add features to a model, preferably by establishing an exclusive parent/child relationship between a set of reference planes and each feature. The reference planes themselves may, but need not be, children of a parent base feature from which a horizontally structured model is developed. Moreover, the reference planes themselves may, but need not be, children of a parent virtual blank model that may correspond to a real-world part or blank in the manufacturing process model. The parent/child relationship means that changes to the parent will affect the child, but changes to the child have no effect upon the parent. Since each added feature of the model is related exclusively to a reference coordinate, then individual features may be added, edited, suppressed or deleted individually without affecting the rest of the model.

Throughout this specification, examples and terminology will refer to Unigraphics® software for illustrative purposes, but the method is not to be construed as limited to that particular software package. Other suitable CAD/CAM software packages that meet the three criteria above and that would therefore be suitable. For example, other suitable software packages include, but may not be limited to, SOLID EDGE®, also by Unigraphics®, and CATIA® by IBM®. Note that the phrases “datum planes”, “parametric modeling” and “features” are phrases derived from the Unigraphics® documentation and may not necessarily be used in other software packages. Therefore their functional definitions are set out below.

“Model” refers to the part that is being created via the CAD/CAM software. The model comprises a plurality of modeling elements including “features”.

“Datum planes” refer to reference features that define Cartesian coordinates by which other features may be referenced to in space. In Unigraphics®, the datum planes are two-dimensional, but a plurality of datum planes may be added to a drawing to establish three-dimensional coordinates. These coordinates may be constructed relative to the model so as to move and rotate with the model. Regardless of how the coordinate system is created, for the purposes of this disclosure it should be possible to reference numerous features to the same coordinate system.

“Parametric modeling capabilities” refers to the ability to place mathematical constraints or parameters on features of the model so that the features may be edited and changed later. Models that do not have this capability i.e., models that include non-editable features, are referred to as “dumb solids”. Most CAD/CAM systems support parametric modeling.

“Features” refers to parts and details that combine to form the model. A “reference feature”, such as a coordinate system, is an imaginary feature that is treated and manipulated like a physical feature, but does not appear in the final physical model.

“Feature modeling” is the ability to build up a model by adding and connecting a plurality of editable features. Not all CAD/CAM software supports this capability. AutoCAD®, for example, currently employs a wire-frame-and-skin methodology to build models rather than feature modeling. An aspect of feature modeling is the creation of associative relationships among models, model elements, features, and the like, as well as combinations of the foregoing, meaning the features are linked such that changes to one feature may alter the others with which it is associated. An exemplary associative relationship is a “parent/child relationship”. “Parent/child relationship” is a type of associative relationship among models, model elements, features, and the like, as well as combinations of the foregoing. For example, a parent/child relationship between a first feature (parent) and a second feature (child) means that changes to the parent feature will affect the child feature (and any children of the child all the way down the familial line), but changes to the child will have no effect on the parent. Further, deletion of the parent results in deletion of all the children and progeny below it. The foregoing definition is intended to address associative relationships created as part of generating a model, notwithstanding associative relationships created as a result of the application of expression driven constraints applied to feature parameters.

The present invention relates to the design and manufacture of a real-world object based upon a virtual CAD/CAM model. An inventive aspect of this method is that the model is horizontally-structured as disclosed in copending, commonly assigned U.S. Pat. No. 6,735,489 U.S. Ser. No. 09/483,301, Filed Jan. 14, 2000, Attorney Docket No. H-204044, entitled “HORIZONTALLY-STRUCTURED MANUFACTURING PROCESS MODELING”, the disclosures of which are incorporated by reference herein in their entirety. An additional inventive aspect of this method is that of the horizontally structured process modeling as disclosed in copending, commonly assigned U.S. Ser. No. 09/483,722, Filed Jan. 14, 2000, Attorney Docket No. DP-301245, entitled “HORIZONTALLY-STRUCTURED CAD/CAM MODELING”, the disclosures of which are incorporated by reference herein in their entirety.

Horizontally-Structured Models

An example of horizontally structured modeling is depicted in FIG.1.FIG. 1 shows the progressive building up of a model through processes depicted at A through J. The actual shape of the model depicted in the figures is purely for illustrative purposes only, and is to be understood as not limiting, in any manner. In the figure, at A, the creation of the first feature of the model, known as thebase feature0 is depicted.

Referring again toFIG. 1, B depicts the creation of another feature, a datum plane that will be referred to as the base-level datum plane1. This is a reference feature as described above and acts as a first coordinate reference. Thearrows13 that flow from the creation of one feature to another indicate a parent/child relationship between the originating feature created and the feature(s) to which the arrow points. Hence, thebase feature0 is the parent of the base-level datum plane. As explained above, any change to the parent will affect the child (e.g., rotate the parent 90 degrees and the child rotates with it), and deletion of the parent results in deletion of the child. This effect ripples all the way down the family line. Since thebase feature0 is the great-ancestor of all later features in the modeling process, any change to the base feature will show up in every feature later created in the process and deletion of the base feature will delete everything. Note that since the base-level datum plane1 is the child of thebase feature0, any change to the base-level datum plane will have no effect upon the base feature, but will affect all its progeny. As a reference coordinate, the base-level datum plane is useful as a positional tool.

It is preferred that the positioning of the base-level datum plane1 with respect to thebase feature0 be chosen so as to make the most use of the base-level datum plane as a positional tool. Note that inFIG. 1, the base-level datum plane1 is chosen to coincide with the center of the cylindrical base feature. By rotating the base-level datum plane symmetrically with the center of the base feature, all progeny will rotate symmetrically about the base feature as well. Differently shaped base features may suggest differently positioned base-level datum planes. Once again, it is noted that datum planes are used here because that is the coordinate system utilized by Unigraphics® software and is therefore illustrative only. Other software or systems may use coordinate reference features that are linear or three-dimensional. It is noteworthy then to appreciate that the teachings disclosed herein are not limited to planar reference features alone and may include various other reference features.

A second coordinate reference may be created as a child of the first coordinate reference described above, though this is not strictly necessary. As seen at C ofFIG. 1, threedatum planes2,3, and4 are created. Each datum plane is oriented orthogonal to the others so that the entire unit comprises a three-dimensional coordinatesystem6. The 3-D coordinatesystem6 thus created is a relative one, meaning it rotates and moves along with the model. This is in contrast to an absolute coordinate system that exists apart from the model and as is common to all CAD/CAM software. Unigraphics® software for example, actually includes two absolute coordinate systems, a “world” coordinate system and a more local “working level” coordinate system.

Referring toFIGS. 1 and 2, there are numerous ways and configurations possible to establish the 3-D coordinatesystem6. For example, three independent datum planes, each referenced to another reference, or three datum planes relative to one another, where afirst datum plane2 may be referenced to a particular reference. A preferred method is to create afirst datum plane2 that is the child of the base-level datum plane1 and offset 90 degrees therefrom. Then, asecond datum plane3 is created as a child of thefirst datum plane2 and is offset 90 degrees therefrom. Note that thesecond datum plane3 now coincides with the base-level datum plane1, but they are not the same plane. It can be seen that any movement of the base-level datum plane1 will result in corresponding movement of first2 and second3 datum planes of the 3-D coordinatesystem6. Thethird datum plane4 of the 3-D coordinatesystem6 is created orthogonal to both the first and second planes, but is a child of thebase feature0 and will preferably coincide with a surface of the base feature. This is preferred with software that requires that physical features be mounted, or “placed”, on a surface though they may be positioned relative to any number of datum planes. While not required, or explicitly enumerated, thethird datum plane4 may further include associative relationships with thefirst datum plane2 andsecond datum plane3, or any other reference plane. The third datum plane of the 3-D coordinate system is therefore referred to as the “face plane,” while the first two datum planes of the 3-D coordinate system are referred to as the “positional planes”. All physical features added to the model from hereon will be “placed” onto the face plane and positioned relative to the positional planes datumplanes2 and3 respectively of the 3-D coordinate system. It will be understood that the abovementioned example of feature placement is illustrative only, and should not be construed as limiting. Any datum plane may operate as a “face plane” for feature placement purposes. Moreover, any feature may also be oriented relative to a reference axis, which may be relative to any reference, which may include, but not be limited to, a datum plane, reference plane, reference system, and the like, as well as combinations of the foregoing.

It is an advantage to using datum planes that features may be placed upon them just as they may be placed upon any physical feature, making the 3-D coordinate systems created from them much more convenient than simple coordinate systems found on other CAD/CAM software. It should be noted, however, that these techniques apply to software that utilize datum planes such as Unigraphics® v-series. For other software, there may, and likely will be, other techniques to establishing a 3-D coordinate system relative to the model to which the physical features of the model may be positioned and oriented. Once, again, this method is not to be construed as limited to the use of datum planes or to the use of Unigraphics® software.

Continuing once again withFIGS. 1 and 2, the system now includes thedatum planes2,3, and4, which may be manipulated by the single base-level datum plane1 so as to affect the positioning of all features added to thebase feature0, but with the constraint that the “placement” of each feature is fixed relative to a face of thebase feature0. This is but one of many possible arrangements but is preferred in the Unigraphics® environment for its flexibility. Movement of the base-level datum plane1 results in movement of the first two positional2,3 planes, but need not necessarily affect thedatum plane4. The result is that objects will move when the base-level datum plane1 is moved, but be constrained to remain placed in the face plane. It is found that this characteristic allows for more convenient and detailed adjustment, though it is a preferred, rather than a mandatory characteristic of the invention.

Referring again toFIG. 1, we see the successive addition of physical features, or form features5athrough5g, to the model at D through J. At D acircular boss5ais mounted to the face plane and positioned relative to the positional planes. At each of E and F, apad5b,5cis added to the model, thereby creating protrusions on either side. At G through J,individual bosses5d,5e,5f, and5gare added to the periphery of the model. Note that in each instance, the new feature is mounted to the face plane and positioned relative to thepositional datum planes2, and3. This means that eachfeature5 is the child of theface datum plane4 and of each of thepositional datum planes2, and3. In the embodiment shown, each feature is therefore a grandchild, great-grandchild, and great-great-grandchild of thebase feature0 by virtue of being a child of theface datum plane4,first datum plane2 andsecond datum plane3, respectively. This means that movement or changes of the base feature results in movement and changes in all aspects of the added features, including both placement and positioning.

Each feature added to the coordinate system of the model is independent of the others. That is to say, in the example depicted inFIG. 1 that no physical feature (except the base feature) is the parent of another. Since no physical feature is a parent, it follows that each individual physical feature may be added, edited, suppressed, or even deleted at leisure without disturbing the rest of the model. This characteristic of the disclosed embodiment that permits model development to proceed approximately at an order of magnitude faster than traditional “vertical” CAD/CAM development. It should be further noted that while the example provided identifies features exhibiting no respective associative relationships, such a characteristic is not necessary. Features may exhibit associative relationships with other features as well as other elements of the model. The constraint this adds is the loss of independence (and hence modeling simplicity) among the several features.

The “vertical” methods of the prior art are graphically depicted in FIG.3 and as taught by the Unigraphics® User's Manual. The column on the right ofFIG. 3 describes the process performed, the central column shows the change to the model as the result, and the leftmost column shows the changing tree structure. Note that here, since there are no datum planes utilized, there are only seven features shown as opposed to the eleven depicted in FIG.1. It is noteworthy to observe the complex tree structure generated when features are attached to one another as depicted inFIG. 3, rather than to a central coordinate system as depicted by FIG.1. Now, further consider what happens if the designer decides that the feature designated “Boss (5a)” (corresponding to5ainFIG. 1) is no longer needed and decides to delete it. According to the tree structure in the lower left ofFIG. 3, deletion of “Boss (5a)” results in the deletion of “Pad (5b)”, “Pad (5c)” and “Boss (5g)”. These features must now be added all over again. It is this duplication of effort that makes traditional “vertical” CAD/CAM design generally frustrating and time-consuming. Employment of the methods disclosed herein utilizing a similar model, suggest reductions of a factor of two in the time required for creation of a model, and time reductions of a factor of ten for making changes to a model.

It should be noted that certain form features may be preferably dependent from other form features or model elements rather than directly dependent as children from the 3-D coordinate system as described herein. For example, an edge blend may preferably be mounted on another physical feature, not a datum plane. Such features will preferably be added to a single physical feature that itself is a child of the 3-D coordinate system, the intent being to keep the lineage as short as possible to avoid the rippling effect of a change whenever a feature is altered or deleted.

It is also noted that additional datum planes may be added as features to the 3-D coordinate system as children just like any physical feature. These would be added as needed to position other physical features, or to place them on surfaces in addition to thedatum plane4. Any additional face planes needed to mount features should be at the same level as the 3-D coordinate system, that is to say a sibling of theoriginal datum plane4, not a child of it. In the example shown, such an added plane would be created as a child of thebase feature0 just as thethird datum plane4 is.

Enhancement To Horizontally Structured Modeling

A first embodiment of the method is depicted and exemplified in FIG.4.FIG. 4 also depicts the progressive building up of a model via process depicted at A′ through J′. The actual shape of the model depicted in the figures is once again, purely for illustrative purposes, and is to be understood as not limiting, in any manner. In this embodiment, a set of coordinate references is established. As seen at A′ ofFIG. 4, three datum planes are created. Similar to the abovementioned horizontally structured modeling disclosure, each datum plane may be oriented orthogonal to the others so that the entire unit comprises a three-dimensional coordinatesystem6. Alternatively, each datum plane or 3-D coordinate system may be positioned and oriented relative to some other reference, for example an absolute reference or coordinate system. For example, the 3-D coordinatesystem6 may be relative to another reference, or an absolute reference such as the reference supplied by the Unigraphics® environment. This means it may rotate and move along with a reference.

A preferred method when utilizing Unigraphics® software is to create afirst datum plane2. Then, asecond datum plane3 is created independent of thefirst datum plane2 and may, but need not be, offset 90 degrees therefrom. Thethird datum plane4 is created, and once again, may be orthogonal to both thefirst datum plane2 andsecond datum plane3, but not necessarily so, thereby formulating the orthogonal 3-D coordinatesystem6.

One advantage to using datum planes is that features may be placed upon them just as they may be placed upon any physical feature, making the 3-D coordinate systems created from them much more convenient than simple coordinate systems found on other CAD/CAM software. It should be noted, however, that these techniques apply to software that utilize datum planes such as Unigraphics®. For other software, there may and likely will be other techniques to establishing a 3-D coordinate system relative to the model to which the physical features of the model may be positioned and oriented. Once, again, this method is not to be construed as limited to the use of datum planes or to the use of Unigraphics® software.

Another feature of this embodiment is that the relation between reference datum planes e.g.,2,3, and4 may, but need not be, associative. Unlike earlier mentioned horizontally structured modeling methods where a parent-child relationship was utilized, in this instance the relationship between the datum planes may be as simple as position and orientation. Once again, the teachings of this invention are not limited to planar reference features.

Turning now to B′ depicted inFIG. 4, abase feature0 is added as a first feature, assembly or a sketch to an existing coordinate system or associative datum plane structure comprisingdatum planes2,3, and4. Where in this instance, unlike the horizontally structured modeling methods described above, there may only be a positional and orientational relationship but not necessarily an associative or parent child relationship among thedatum planes2,3, and4. The elimination of an associative relationship among thedatum planes2,3, and4, the 3-D coordinatesystem6, and thebase feature0 provides significant latitude in the flexibility attributed to the 3-D coordinatesystem6 and thebase feature0. Therefore, the datum plane structure comprising2,3, and4 may take its place as the zero'th level feature of the model. Thereafter, thebase feature0 is added at B′ and the physical features, or form features5a-5gare added at D′ through J′ in a manner similar to that described earlier. However, once again, it is noteworthy to appreciate that here a parent child relationship is eliminated between thebase feature0 and the physical features, or form features5a-5g. In addition, an associative relationship, in this case a parent child relationship is created between the physical features, or form features5a-5gand thedatum planes2,3, and4.

It may be beneficial to ensure that the positioning of thebase feature0 with respect to thedatum planes2,3, and4 be chosen so as to make the most use of thebase feature0 as an interchangeable element. Note once again fromFIG. 1, in that embodiment, the base-level datum plane was chosen to coincide with the center of the cylindrical base feature. By rotating the base-level datum plane symmetrically with the center of the base feature, all progeny will rotate symmetrically about the base feature as well. Differently shaped base features will suggest differently positioned base-level datum planes. In this embodiment, the physical features, or form features5a-5gand thedatum planes2,3, and4 maintain an associative relationship, but neither with thebase feature0. When the 3-D coordinate system is established before the fundamental shape is placed on the screen and presented to the user, it simplifies substitution of thebase feature0 to other models. For example, where it may be desirable to change onebase feature0 for another, and yet preserve the later added physical features, or form features e.g.,5a-5g. The disclosed embodiment simplifies this process by eliminating the parent child relationship between thebase feature0 and the datum planes. Therefore thebase feature0 may be removed and substituted with ease. Moreover, the physical features, or form features5a-5gand thedatum planes2,3, and4 may easily be adapted to other base features of other models.

The Manufacturing Process

The manufacturing process of a disclosed embodiment utilizes the horizontal CAD/CAM methods described above to ultimately generate process instructions and documentation used to control automated machinery to create a real-world part based on a horizontally-structured model. In a preferred method, “extracts” are used to generate process sheets or other instructions for each requirement for machining of the real-world part.

Referring toFIGS. 5 and 6, to initiate the manufacturing process and virtual machining, a suitable blank may be selected or created, usually a cast piece, the dimensions and measurements of which are used as the virtual blank10 for the virtual machining of the 3-D parametric solid model with the horizontally structured manufacturing method. Alternatively, a virtual blank10 may be selected, and a blank manufactured to match. For example, in the Unigraphics® environment, a suitable blank or component is selected, a virtual blank10 is generated therefrom, commonly a referenced set of geometries from a model termed a reference set26 (e.g., a built up product model of a part). From this referenced set of geometries a three-dimensional (3-D) parametric solid model termed a virtual blank10 may be generated or created for example via the Wave link or Promotion process of Unigraphics®, which includes all of the modeled details of the completed part.

Once a virtual blank10 has been established that corresponds to a real-world blank, a horizontally-structured 3-D parametric solid model is created in a manner that describes machining operations to be performed on the blank so as to produce the final real-world part. This horizontally structured model will be referred to as themaster process model20. It is noteworthy to appreciate that themaster process model20 depicted includes with it, but is not limited to, the virtual blank10, added manufacturing features12a-12jby way of virtual machining, anddatum planes2,3, and4 all in their respective associative relationships as exhibited from the geometries and characteristics of the reference set26.

FIG. 6 depicts the virtual machining process of the exemplary embodiment where manufacturing features are “machined” into the virtual blank10. For example, at N, O, and P various holes are “drilled” into the virtual blank10 as manufacturing features12a,12b, and12crespectively. Moreover, at S a large hole is created via a boring operation at12f. It is also noted once again, just as in the horizontally structured modeling methods discussed above, that thedatum planes2,3, and4 may be added as features to the 3-D coordinate system as children just like any form feature (e.g.,5a-5g) ormanufacturing feature12a-12j. These may be added as needed to position other features, or to place them on surfaces in addition to thedatum planes2,3, and4. For example as shown inFIG. 6 at V, such an added plane may be created as a child of the virtual blank10 just as thethird datum plane4 is. Moreover, at V the model has been flipped around and aface plane7 is placed on the back as a child of the virtual blank10. This allows manufacturing features12iand12jto be placed on the back of the object, in this case “counter-bores” for the holes “drilled” through the front earlier.

One may recognize themaster process model20 as the completed horizontally structured model depicted at W inFIG. 6 including all of the “machining” operations. Referring again toFIG. 4, some CAD/CAM software packages may require that the addition of the features be in a particular order, for example, in the same order as manufacture. In such a case a method for reordering the features is beneficial. In this case, the reordering method is a displayed list offeatures24 that the user may manipulate, the order of features in the list corresponding to that in themaster process model20. Process instructions and documentation termedprocess sheets23 are then generated from each operation. Theprocess sheets23 are used to depict real-time in-process geometry representing a part being machined and can be read by machine operators to instruct them to precisely machine the part. An example of a Unigraphics® process sheet23 is shown in FIG.7. The geometry can then be used to direct downstream applications, such as cutter paths for Computer Numerical Code (CNC) machines. In an embodiment, the software is adapted to generate such CNC code directly and thereby control the machining process with minimal human intervention, or even without human intervention at all. For example, in the Unigraphics® environment, CNC code is generated by the Manufacturing software module, which is configured to automate the machining process.

The traditional approach to manufacturing modeling is to create individual models representing the real-world component at particular operations in the manufacturing process. If a change or deletion is made in one model, it is necessary to individually update each of the other models having the same part. Using the horizontally structured modeling disclosed herein, it is now possible to generate a horizontally structuredmaster process model20 and generate a set ofprocess sheets23 that are linked thereto. Any changes to themaster process model20 are reflected in all theprocess sheets23.

As seen inFIG. 5, this linkage between themaster process model20 and theprocess sheets23 is preferably achieved through the use of extracted in-process models, called virtual extract(s) or extracted bodies, hereinafter denoted extract(s)22, that are time stamped and linked to themaster process model20. Eachextract22 represents part of the manufacturing process and each is a child of themaster process model20. Any changes to themaster process model20 are automatically reflected in all the relevant extract(s)22, but changes to the extract(s)22 have no effect on themaster process model20. Eachextract22 is a three-dimensional snapshot of themaster process model20 at a moment in “time” of its creation. Theextracts22 created for each operation are children of themaster process model20. By changing themaster process model20, theextracts22, and therefore, the manufacturing process is automatically updated.

The order of creation of theextracts22 is preferably dictated by a user-friendlygraphical interface21, hereinafter referred to as amodel navigation tool21. Themodel navigation tool21 will preferably allow the user to arrange the order of features through simple mouse operations so as to make manipulation of themaster process model20 as simple and intuitive as practicable. In the Unigraphics® software, a model navigation tool provides similar functionality and capability. In the example depicted atFIG. 6, aprocess sheet23 is generated for eachextract22 in one-to-one correspondence. Since themaster process model20 is preferably created using the horizontally-structured methods described above, editing themaster process model20 is a simple and expedited matter of adding, editing, suppressing, or deleting individual features of themaster process model20, which through the extract(s)22 will automatically update all the process sheet(s)23. In a similar example, the disclosed method of generating process sheets has resulted in a 50% reduction in the time needed to create new process sheets and an 80% reduction in the time required to revise existing process sheets over the “vertical” modeling methods.

Further, this principle may be extended downstream in the manufacturing process model by utilizing the electronic data for CNC programs, tooling (i.e., cutting tool selection), and fixture design by direct transmission to the machining tools without the need forprocess sheets23 and human intervention. For example, in the Unigraphics® environment, this may be achieved by creating a reference set to theparticular extract22 and including it in to a new file via virtual assembly, similar to the method employed for the creation of the virtual blank10 discussed earlier. Theextract22 therefore, is used to create the corresponding geometry. Software must then be provided to adapt the CAD/CAM software to translate the geometry into CNC form.

The method leading to generatingprocess sheets23 initiates with selection of a virtual blank10 and then proceeding to add via virtual machining, manufacturing features (12a-12j) to the virtual blank10 in a horizontally-structured manner as described earlier. Following each virtual machining operation, anextract22 is made representing the state of themaster process model20 at that instant of the manufacturing process. The order in which the features are machined onto the real-world part is decided either through automated means or manually by the user with themodel navigation tool21. In the Unigraphics® environment an “extract” is then preferably made of themaster process model20 corresponding to each added feature representing a manufacturing position or operation. The “extraction” is accomplished through a software module provided with the CAD/CAM software, otherwise the user may create a software program for the process. In Unigraphics® software, a Modeling Module includes software configured to handle the extraction process. Theprocess sheets23 may then be created from theextracts22 that are added into the Drafting Module of the Unigraphics® software.

One may think of anextract22 as a three-dimensional “snapshot” of the assembly of themaster process model20 in progress, showing all of the manufacturing features12a-12jup to that operation in the assembly, but none that come after it. Theprocess sheet23 derived from theextract22 contains the instructions to machine the latest feature that appears at that “snapshot” in time. In the Unigraphics® environment, anextract22 is an associative replica ofmaster process model20 depicting only those features, which have been added to that point in the manufacturing process. It is noteworthy to appreciate that; manufacturing features12a-12jmay thereafter be added to theextract22 without appearing in themaster process model20, however anymanufacturing features12a-12jadded to themaster process model20 will appear in theextract22 if the particular manufacturing feature (e.g. one of12a-12j) is directed to be added at or before the manufacturing procedure represented by theextract22.

Referring toFIGS. 5 and 7, there is shown atypical process sheet23. Aprocess sheet23 is a document defining the sequence of operations, process dimensions, and listing of equipment, tools, and gauges required to perform an operation. Manufacturing personnel utilize process sheets to obtain the detailed information required to manufacture and inspect the components depicted thereon. Eachprocess sheet23 includes, but is not limited to, both graphics and text. The graphics may include the dimensional characteristics of the part for the particular portion of the manufacturing process, the text contains various data identifying the part and operation and noting revisions. In the example shown inFIG. 7, we see a part called a “Tripod Joint Spider.” The operation that this process sheet depicts isnumber10 in a set of operations and is described as a “drill, chamfer and ream” and it may be seen by the graphics that a 41 mm hole is to be drilled through the part and chamfered out 48 deg from the central axis of the hole (or 42 deg from the surface of the spider joint) on both sides.

Enhancement to Horizontally Structured Manufacturing Process Modeling

A first alternative embodiment of the manufacturing process is disclosed which utilizes the horizontal CAD/CAM modeling methods described above to ultimately generate process instructions and documentation used to control automated machinery to create a real-world part based on a horizontally-structured model. In a preferred method, process model “extracts” are used to generate process sheets or other instructions for each procedure to machine the real-world part.

Referring toFIG. 8, to initiate the manufacturing process and virtual machining, once again, a suitable blank may be selected or created, for example, a cast piece, the dimensions and measurements of which, are used as the virtual blank10 for the virtual machining of the 3-D parametric solid model with the horizontally structured manufacturing method. Alternatively, a virtual blank10 may be selected, and a blank could be manufactured to match it. This alternative may prove be less desirable as it would incorporate additional machining which would not be necessary if the virtual blank10 initiates with the blank's dimensions. It is nonetheless stated to note that the method disclosed includes, and is not limited to a variety of approaches for establishing the blank and a representative virtual blank10 for the model.

For example, in the Unigraphics® environment, a suitable blank or component is selected. A virtual blank10 is generated therefrom, commonly a referenced set of geometries from a model termed a reference set26 shown inFIG. 9 (e.g., a built up product model of a part). From this referenced set of geometries a three-dimensional virtual blank10 model may be generated or created for example via the Wave link or Promotion process of Unigraphics®, which includes all of the modeled details of the completed part.

Once a virtual blank10 has been established that corresponds to a real-world blank, a horizontally-structured 3-D parametric solid model is generated or created in a manner that describes machining operations to be performed on the blank so as to produce the final real-world part. This horizontally structured model will be referred to as themaster process model20. It is noteworthy to appreciate that themaster process model20 depicted includes with it, but is not limited to, the virtual blank10, added manufacturing features12a-12jby way of virtual machining, anddatum planes2,3, and4 all in their respective associative relationships as exhibited from the geometries and characteristics of the reference set26.

Themaster process model20, logically, is a child of the reference set26 and virtual blank10, thereby ensuring that if a design change is implemented in the product model utilized for the reference set26, such a change flows through to themaster process model20 and manufacturing process. Unique to this embodiment, is the lack of a mandatory associative relationship among themaster process model20 and thedatum planes2,3, and4 which comprise the reference 3-D coordinatesystem6 with respect to which, the form features and manufacturing features are positioned and oriented. Moreover, also unique to this embodiment, is the absence of a mandatory associative relationship among thedatum planes2,3, and4 themselves. This independence, as with the modeling described above provides significant flexibility in the manufacturing process by allowing a user to interchangeably apply various features to a master process model. Likewise, interchangeable master process models may be generated without impacting the particular features or datum planes utilized.

Referring once again toFIG. 6, the virtual machining process of the exemplary embodiment where manufacturing features are “machined” into the virtual blank10 is depicted. For example, at N, O, and P various holes are “drilled” into the virtual blank10 as manufacturing features12a,12b, and12crespectively. Moreover, at S a large hole is created via boring operation at12f. It is also noted once again, just as in the horizontally structured modeling methods discussed above, that thedatum planes2,3, and4 may be added as features to the 3-D coordinate system as children just like any form feature (e.g.,5a-5g) ormanufacturing feature12a-12j. These may be added as needed to position other features, or to place them on surfaces in addition to thedatum planes2,3, and4. For example as shown inFIG. 6 at V, such an added plane may be created as a child of the virtual blank10 just as thethird datum plane4 is. Moreover, at V the model has been flipped around and aface plane7 is placed on the back as a child of the virtual blank10. This allows manufacturing features12iand12jto be placed on the back of the object, in this case “counter-bores” for the holes “drilled” through the front earlier.

Once again, one may recognize themaster process model20 as the completed horizontally structured model depicted at W inFIG. 6 including all of the “machining” operations. Referring again toFIG. 8, similar to the horizontally structured modeling disclosure above, some CAD/CAM software packages may require that the addition of the manufacturing features12a-12jto be in a particular order, for example, in the same order as manufacture. In such a case, a method for reordering the features may prove beneficial. In this case, the reordering method is a displayed list offeatures24 that the user may manipulate, the order of features in the list corresponding to that in themaster process model20. Here again, as stated earlier, process instructions and documentation termedprocess sheets23 are then generated from each operation. Theprocess sheets23 are used to depict real-time in-process geometry representing a part being machined and can be read by machine operators to instruct them to precisely machine the part. Once again, an example of a Unigraphics® process sheet23 is shown in FIG.7. The geometry can then be used to direct downstream applications, such as cutter paths for Computer Numerical Code (CNC) machines. In a preferred embodiment, the software is adapted to generate such CNC code directly and thereby control the machining process with minimal human intervention, or even without human intervention at all.

The traditional approach to manufacturing modeling was to create individual models representing the real-world component at particular operation in the manufacturing process. If a change or deletion was made in one model, it was necessary to individually update each of the other models having the same part. Using the horizontally structured modeling disclosed herein, it is now possible to generate a horizontally structuredmaster process model20 and generate a set ofprocess sheets23 that are linked thereto. Any changes to themaster process model20 are reflected in all theprocess sheets23.

As seen inFIG. 8, in Unigraphics® software, this linkage between themaster process model20 and theprocess sheets23 is preferably achieved through the use of extracted in-process models, called virtual extract(s) or extracted bodies, hereinafter denoted extract(s)22, that are time stamped and linked to themaster process model20. Referring also toFIG. 9, eachextract22 is also a three dimensional solid model and represents the part under fabrication at a particular operation or time in the manufacturing process. Eachextract22 is a child of themaster process model20. Any changes to themaster process model20 are automatically reflected in all the relevant extract(s)22, but changes to the extract(s)22 have no effect on themaster process model20. It should be noted that in an exemplary embodiment, eachextract22 need not necessarily exhibit an associative relationship with thedatum planes2,3, and4 respectively nor the manufacturing features12a-12jrespectively. An advantage of the disclosed embodiment then is, in the realization that any changes to thedatum planes2,3, and4 as well as the manufacturing features12a-12jare independent of the relevant extract(s)22 and vice versa. An additional characteristic of the exemplary embodiment is that each of the manufacturing features12a-12j, now maintain associative relationships, in this case, parent/child relationships with thecorresponding datum planes2,3, and4. Therefore, changes to the datum planes are automatically reflected in all the relevant manufacturing features12a-12j, but changes to the manufacturing features12a-12jhave no effect on the various datum planes. Once again, the manufacturing features12a-12jmay, but need not necessarily, exhibit an associative relationship among themselves. This separation of the associative relationships ofmaster process model20 and extracts22 fromdatum planes2,3, and4 andmanufacturing features12a-12jis one characteristic, which enables a user now to effectively manipulate the various elements of the manufacturing process models to facilitate easy substitutions into or out of a model.

Continuing withFIG. 8, eachextract22 is a three-dimensional “snapshot” of themaster process model20 at a moment in “time” of its creation in the manufacturing process. Theextracts22 created for each operation are children of themaster process model20. By changing themaster process model20, theextracts22, and therefore, the manufacturing process is automatically updated.

The order of creation of theextracts22 is preferably dictated by a user-friendlygraphical interface21, hereinafter referred to as amodel navigation tool21. Themodel navigation tool21 will preferably allow the user to arrange the order of features through simple mouse operations so as to make manipulation of themaster process model20 as simple and intuitive as practicable. In the Unigraphics® software, a model navigation tool provides similar functionality and capability. Aprocess sheet23 is generated for eachextract22. In the example depicted inFIG. 8, aprocess sheet23 is generated for each extract in one-to-one correspondence. Since themaster process model20 is preferably created using the horizontally-structured methods described above, editing themaster process model20 is a simple and expedited matter of adding, editing, suppressing, or deleting individual features of themaster process model20, which, through the extract(s)22, will automatically update all the process sheet(s)23.

Further, this principle may be extended further downstream in the manufacturing process model by utilizing the electronic data for CNC programs, tooling (i.e., cutting tool selection), and fixture design by direct transmission to the machining tools without the need forprocess sheets23 and human intervention. For example, in the Unigraphics® environment, such automation may be achieved by creating a reference set (analogous to the reference set26) to theparticular extract22 and including it in a new file via virtual assembly, similar to the method employed for the creation of the virtual blank10 discussed earlier. Theextract22 therefore, is used to create the corresponding geometry. Software must then be provided to adapt the CAD/CAM software to translate the geometry into CNC form.

The method of generatingprocess sheets23 initiates with selection a virtual blank10 and then proceeding to addmanufacturing features12a-12j(FIG. 6) to the virtual blank10 in a horizontally-structured manner as described earlier. Following each virtual machining operation, anextract22 is made representing the state of themaster process model20 at that instant of the manufacturing process. The order in which the features are to be machined into the real-world part is decided upon either through automated means or manually by the user with themodel navigation tool21. In the Unigraphics® environment an “extract” is then preferably made of themaster process model20 corresponding to each added feature representing a manufacturing position or operation. The “extraction” is accomplished through a software module provided with the CAD/CAM software, otherwise the user may develop software to program the process. In Unigraphics® software, the Modeling Module includes software to handle the extraction process. Once again, theprocess sheets23 may then be created from theextracts22 that are added into the Drafting Module of the Unigraphics® software.

Once again, one may think of anextract22 as a “snapshot” of the assembly of themaster process model20 in progress, showing all of the manufacturing features (e.g. one or more of12a-12j(FIG.6)) up to that point in the assembly, but none that come after it. Theprocess sheet23 derived from theextract22 contains the instructions to machine the latest feature that appears at that “snapshot” in time. In the Unigraphics® environment, anextract22 is an associative replica ofmaster process model20 depicting only those features, which have been added to that point in the manufacturing process. It is noteworthy to appreciate that, manufacturing features12a-12jmay be added to theextract22 without appearing in themaster process model20, however any features added to themaster process model20 will appear in theextract22 if the feature is directed to be added at or before the manufacturing procedure represented by theextract22.

Referring toFIG. 8, there is shown atypical process sheet23. Once again, aprocess sheet23 is a document defining the sequence of operations, process dimensions, and listing of equipment, tools, and gauges required to perform an operation. Manufacturing personnel utilize process sheets to obtain the detailed information required to manufacture and inspect the components depicted thereon. Eachprocess sheet23 includes, but is not limited to, both graphics and text. Again, the graphics may include, but not be limited to, the dimensional characteristics of the part for the particular portion of the manufacturing process, the text may include, but not be limited to various data identifying the part and operation and noting revisions, and corresponding tooling fixtures and gauges, and the like. Once again, an example is shown inFIG. 7, with the same characteristics as described earlier.

Enhancement to Horizontally Structured Modeling and Manufacturing Process Modeling Employing Model Link/Unlink

Another feature of the horizontally structured modeling and manufacturing process modeling is disclosed which utilizes the horizontal CAD/CAM modeling methods described above. Specifically, the first embodiment is further enhanced to ultimately generate CAD/CAM models and process sheets that are used to control automated machinery to create a real-world part based on a horizontally structured CAD/CAM models. In an exemplary embodiment, horizontally structured modeling methods and horizontally structured manufacturing process modeling methods as disclosed above are employed to facilitate the generation of one or more manufacturing process models for creating the actual part. This manufacturing process model is termed a master process model. “Extracts” of master process models are utilized to generate process sheets or other instructions for each procedure to machine a real-world part.

To facilitate the method disclosed and model creation, a link and unlink functionality is disclosed which provides for automatic references and the modification of links associative relationships among one or more CAD/CAM models and model elements. The link/unlink function allows a newly created or existing model or model element to be replaced by another. Moreover, the features associated with a first model may be reassociated to another model with little if any impact to the associated features.

In the Unigraphics® environment, the exemplary embodiment takes advantage of the existing link and unlink functionality of the Unigraphics® CAD/CAM system software. In the exemplary embodiment, an illustration employing Unigraphics® software is employed. The disclosed method includes the removal of feature dependency between modeling elements, in this instance a master process model generated as disclosed earlier, and a linked geometry. Therefore, enabling the linked geometry to be replaced by a new geometry without losing the prior positional and orientational dependencies associated with the linked geometry. Therefore, this capability maintains the associative relationships generated between a linked geometry and a master process model.

Referring toFIGS. 9 and 10, and continuing withFIGS. 6 and 8, for a better understanding of the features of the disclosed embodiment, reference is made to the earlier disclosed enhanced modeling and enhanced manufacturing process disclosures, as well as exemplified below. Therefore, the disclosure will be in reference to a manufacturing process modeling but is not to be construed as limited thereto. In reference to the manufacturing process and virtual machining, once again, a suitable blank may be selected or created, a cast piece for instance, the dimensions and measurements of which, are used as the virtual blank10 for the virtual machining of the 3-D parametric solid model with the horizontally structured manufacturing method. Alternatively, once again, a virtual blank10 may be selected, and a blank could be manufactured to match it. Once again, this alternative may prove be less desirable as it would incorporate additional machining which would not be necessary if the virtual blank10 initiates with the blank's dimensions. It is nonetheless restated to note that the method disclosed includes, and is not limited to a variety of approaches for establishing the blank and a representative virtual blank10 for the model. For example, again in the Unigraphics® environment, a suitable blank or component is selected. A virtual blank10 may be generated therefrom, commonly a referenced set of geometries from a model termed a reference set26 (e.g., a built up product model of a part). From this referenced set of geometries a three-dimensional virtual blank10 model may be generated or created via the Wave link or Promotion process of Unigraphics®, which includes all of the modeled details of the completed part.

Once a virtual blank10 has been established that corresponds to a real-world blank, a horizontally-structured 3-D parametric solid model is generated or created in a manner that describes machining operations to be performed on the blank so as to produce the final real-world part. This horizontally structured model is again referred to as themaster process model20. It is noteworthy to appreciate that themaster process model20 depicted includes with it, but is not limited to, the virtual blank10, added manufacturing features12a-12j(FIG. 6) by way of virtual machining, anddatum planes2,3, and4 all in their respective associative relationships as exhibited from the geometries and characteristics of the reference set26.

Themaster process model20 is a 3-D parametric solid model representative of the geometry of a reference set26, which includes the reference set26 associative relationships. Moreover, themaster process model20 may be manipulated and modified as required to model the process of fabricating the actual part. Once again, thismaster process model20, logically, is a child of the reference set26. Moreover, once again, no mandatory associative relationship need exist among the master process model20 (e.g., in a Unigraphics® environment, the Wave linked geometry) and thedatum planes2,3, and4 which comprise the reference 3-D coordinatesystem6 with respect to which, the features are positioned and oriented or among thedatum planes2,3, and4.

The described independence, as with the modeling described above provides significant flexibility in the manufacturing process by allowing a user to interchangeably apply various features to a particularmaster process model20. Likewise, interchangeablemaster process models20 may be generated without impacting the particular features or datum planes (e.g.,2,3, and4) utilized. For example, different reference sets or geometries may be selected and a new master process model generated therefrom and subsequently, the same features and associated datums added. Referring once again toFIG. 6, the virtual machining process of the exemplary embodiment where manufacturing features are “machined” into the virtual blank10 is depicted. The process is similar to that disclosed above and therefore, need not be repeated.

Once again, one may recognize themaster process model20 as the completed horizontally structured model depicted at W inFIG. 6 including all of the “machining” operations. Once again, some CAD/CAM software packages may require that the addition of the manufacturing feature(s)12a-12jto be in a particular order, for example, in the same order as manufacture. Once again, in such a case, a method for reordering the features may prove beneficial.

It is noteworthy to appreciate that the link/unlink capability realizes its potential and significance primarily due to the characteristics of the horizontally structured model and manufacturing processes disclosed herein. Specifically, the separation/distribution of associative relationships in the models provides the enhancement achieved.

In contrast, in “vertical” modeling and traditional manufacturing processes, where the traditional approach to manufacturing modeling was to create separate individual models representing the real-world component at numerous particular operations in the manufacturing process. If a change or deletion was made in one model, it was necessary to individually update each of the other models having the same part. Using the horizontally structured modeling disclosed herein and employing the model link/unlink capabilities, it is now possible to generate multiple horizontally structured master process models linked in a manner such that changes in one model are automatically carried out in other linked models. Further, thesubsequent process sheets23 that are linked thereto are also automatically updated. Any changes to themaster process model20 are reflected in all theprocess sheets23.

Once again, as seen inFIG. 10, in Unigraphics® software, this linkage between themaster process model20 and theprocess sheets23 is preferably achieved through the use of extracted in-process models, called virtual extracts(s) or extracted bodies, hereinafter denoted as extract(s)22, that are time stamped and linked to themaster process model20 as disclosed above. Referring also toFIG. 8, eachextract22 is also a three dimensional solid model and represents the part under fabrication at a particular operation or time in the manufacturing process and includes the properties as described in earlier embodiments.

In the example depicted inFIG. 10 in a manner similar to that depicted inFIG. 8, aprocess sheet23 is generated for eachextract22 in one-to-one correspondence as described earlier. Since themaster process model20 is preferably created using the horizontally-structured methods described above, editing themaster process model20 is a simple and expedited matter of adding, editing, suppressing, or deleting individual features of themaster process model20, which through the extract(s)22, will automatically update all the process sheet(s)23.

Once again, this principle may be extended further downstream in the manufacturing process model by utilizing the electronic data for CNC programs, tooling (i.e., cutting tool selection), and fixture design by direct transmission to the machining tools without the need forprocess sheets23 and human intervention.

Horizontally Structured Modeling Manufacturing Process Modeling For Alternate Operations

The model link/unlink functionality coupled with the horizontally structured process modeling as disclosed earlier brings forth new opportunities for enhancement of CAD/CAM modeling manufacturing processes. One such opportunity is horizontally structured CAD/CAM modeling and manufacturing process modeling methods to facilitate alternate operations and manufacturing processes. For a better understanding of the features of the disclosed enhancement, reference is made to the earlier disclosed horizontally structured modeling and horizontally structured manufacturing process modeling including model link/unlink disclosed above, and as exemplified below.

Referring toFIG. 11, in the disclosed method, horizontally structured modeling methods as disclosed above are employed to facilitate the generation of one or more manufacturing process models for creating the actual part. This manufacturing process model is termed a master process model. “Extracts” of master process models are utilized to generate process sheets or other instructions for each procedure to machine a real-world part just as described above.

To facilitate the method disclosed and model creation, the link/unlink and extraction function disclosed above is employed to facilitate performing an alternative manufacturing process. The alternative manufacturing process may be initiated via the “extraction” process of an existing model generating an alternate master process model e.g., a replica of a first or existing model. The existing model may include, but not be limited to, a reference set, a newly created master process model, or an existing master process model.

In an exemplary embodiment, an illustration employing Unigraphics® software is disclosed. The disclosed method includes the creation of amaster process model20, and performing virtual machining thereon, followed by the generation ofextracts22 and process sheets in a manners as disclosed above. Additionally, an alternatemaster process model30 is generated and likewise, followed by the generation of alternate extract(s)32 and ultimately alternate process sheet(s)33 therefrom. Thereby, multiple alternate processes for manufacturing operations may be created.

For a better understanding of the features of the disclosed embodiment, reference is made to the earlier disclosed modeling and manufacturing process disclosures as well as exemplified below. Referring toFIG. 11, the enhancement is described by illustration of additional features subsequent to the abovementioned embodiments, specifically an enhancement to the manufacturing process modeling. Therefore, the disclosure will be in reference to a manufacturing process modeling but is not to be construed as limited thereto.

In reference also to FIG.10 and once again FIG.8 and to the manufacturing process modeling, once again, amaster process model20 is created and includes the characteristics, relationships and limitations as described above. To avoid duplication, reference may be made to the abovementioned embodiments for insight concerning the generation or creation of a master process model and any characteristics thereof.

Turning now toFIG. 11 for insight into the application of a reference set26,master process model20, and the extracted alternatemaster process model30. In one or more sets of process models, as disclosed in the abovementioned embodiments, one or more extract(s) may be generated from themaster process model20. From the extract(s)22, corresponding process sheets may also be generated. To facilitate alternate manufacturing operations, however, the alternatemaster process model30 is created following the completion of the “virtual” machining of the desired common manufacturing features (e.g.12a, and12bfor instance). The alternatemaster process model30 may be extracted once again from the last in-process process model22 including the particular manufacturing features desired to generate a new 3-D parametric solid model to facilitate the definition of an alternate process of manufacturing. Alternate machining operations to add alternative manufacturing features for example, may be performed on the alternatemaster process model30. Once again, in a similar manner to the above-mentioned embodiments, extracts may be made during the virtual machining process and therefrom process sheets generated. Where the extracts, in this case termedalternate extracts32 of the alternatemaster process model30 are created at various operations of the manufacturing process, in this case the alternate manufacturing process. Once again from thesealternate extracts32,alternate process sheets33 may be generated for specifying the manufacturing operations.

It is noteworthy to appreciate that the alternate manufacturing operations process capability disclosed realizes its potential and significance primarily due to the characteristics of the horizontally structured model and manufacturing processes disclosed herein. Specifically, the separation/distribution of associative relationships in the models provides the enhancement achieved. In contrast, in “vertical” modeling and traditional manufacturing processes, where the traditional approach to manufacturing modeling was to create separate individual models representing the real-world component at numerous particular operations in the manufacturing process. If a change or deletion was made in one model, it was necessary to individually update each of the other models having the same part. Using the horizontally structured modeling disclosed herein and employing the model link/unlink capabilities, it is now possible to generate multiple a horizontally structured alternate master process model(s)30 linked in a manner such that changes in one model are automatically carried out in other linked models enabling a multitude of alternate manufacturing processes. Further, the subsequentalternate process sheets33 that are linked thereto are also automatically updated. Any changes to the alternatemaster process model30 are reflected in all thealternate process sheets33.

Horizontally Structured Modeling Manufacturing Process Modeling For Multiple Master Process Models

The model link/unlink functionality coupled with the horizontally structured process modeling as disclosed earlier brings forth new opportunities for enhancement of CAD/CAM modeling and manufacturing process modeling. One such opportunity is horizontally structured CAD/CAM modeling and manufacturing process modeling methods to facilitate large-scale manufacturing processes incorporating a large (e.g. more than 50 operations) number of manufacturing operations. For a better understanding of the features of the disclosed embodiment, reference is made to the earlier disclosed horizontally structured modeling and horizontally structured manufacturing process modeling including model link/unlink disclosed above, and as further exemplified below.

In current large-scale manufacturing process models, generally a separate file with separate models is created for each manufacturing operation, none of the files or models linked in any associative relationship across individual files or models. Such a configuration, dictates that a change made in one model or file that reflects upon others must be manually entered for each of the affected files. For manufacturing processes employing a larger number of operations, such a method becomes unwieldy. In addition, in most CAD/CAM software systems manufacturing process models of such a sort tend to be very large software files (e.g., commonly 40-50 megabytes). Such large files are cumbersome for computer system to utilize and result in delays for a user.

In horizontally structured manufacturing process models as described above, for manufacturing processes employing a large number of operations, the situation is not much different. The master process model and each of the extracted in process models are part of a single file which once again can become unwieldy and burdensome for the user. The situation may be improved somewhat by employing separate files. However, such an approach leads to separate process models that once again include no linkage or associative relationships among the separate files. Therefore, in this case, each separate model would, once again, require manual updates to reflect any changes in the product casting or the manufacturing process.

For a better understanding of the features of the disclosed embodiment, reference is made to the earlier disclosed modeling and manufacturing process disclosures as well as exemplified below. The embodiment is described by illustration of additional features subsequent to the abovementioned embodiments, specifically an enhancement to the horizontally structured manufacturing process modeling disclosed and claimed herein. Therefore, the disclosure will be in reference to and illustrated using manufacturing process modeling but is not to be construed as limited thereto.

In the disclosed embodiment, horizontally structured modeling methods and the part link/unlink embodiments as disclosed above are employed to facilitate the generation of a manufacturing process for creating an actual part (e.g., a method for modeling and performing a large number of manufacturing operations). The manufacturing process comprises a plurality of models each termed master process models analogous to those described above. In this instance, each of the master process models are generated and configured in a hierarchy and include associative relationships (e.g. links) configured such that changes in a “senior” master process model are reflected in all the subsequent or “junior” linked master process models. However, changes in the subsequent or “junior” master process models will not affect the more “senior” master process models. “Extracts” of each master process model are utilized to generate process sheets or other instructions for each procedure to machine a real world part just as described in earlier embodiments. Thereby, the combination of the multiple processes enabling large-scale manufacturing operations may be created. Referring toFIG. 12, to facilitate the method disclosed and large-scale model creation, once again, the link/unlink and extraction functions disclosed above are once again employed. To execute generating a large-scale manufacturing process, multiple master process models e.g.,20a,20b, and20care created each including a subset of the manufacturing operations required to complete the total manufacturing requirements. In the figure, by way of illustration of an exemplary embodiment, three suchmaster process models20a,20b, and20care depicted. Eachmaster process model20a,20b, and20cis created in a separate file, the files linked in associative relationships as depicted by the arrows in the figure. Once again, themaster process model20a,20b, and20cmay be created or generated in a variety of manners as described above. For example, in the Unigraphics® environment, themaster process model20 may be generated via virtual machining of a virtual blank10, which was an “extraction” from a reference set26, as a replica of an existing model. Once again, a master process model is created and includes the characteristics, relationships and limitations as described in the abovementioned embodiments. To avoid duplication, reference may be made to the above-mentioned embodiments for insight concerning a master process model and horizontally structured models.

Referring once again toFIG. 12, each of themaster process models20a,20b, and20care configured in a hierarchy, in three separate files and include associative relationships (e.g. links) configured such that changes in a “senior” (e.g.,20a,20b, and20crespectively) master process model are reflected in all the subsequent linked master process models (e.g.,20band20c). However, changes in the subsequent master process models (e.g.,20c, and20b, respectively) will not affect the prior master process models. Moreover the master process models are created, configured and linked with associative relationships such that changes to the reference set26 or virtual blank10 from which they originated, flow down to allmaster process models20a,20b, and20crespectively.

An exemplary embodiment further illustrates application to a large scale manufacturing process. A “senior” master process model, e.g.,20ais generated as disclosed herein, namely initiated with a virtual blank10 as a replica of the desired reference set26, virtual blank10, or a product casting. The virtual machining necessary to add a first subset of all the desired manufacturing features for example,12a, and12bis performed. Following the addition of the first subset of manufacturing features, a second or junior master process model e.g.,20bin a separate file is generated from the first e.g.20a. The subsequent desired manufacturing features to be associated with the second master process model e.g.,12c, and12dare added to the second master process model e.g.,20b. Finally, as illustrated in the figure, a third master process model e.g.,20cis generated from the second e.g.,20bin yet another separate file and further subsequent manufacturing features e.g.,12eand12fare added. Subsequent “junior” master process models may be generated in subsequent separate files as needed to accomplish the entire large scale manufacturing process and yet keep the individual file size manageable. A particular feature of the exemplary embodiment is that it would allow the user to readily add new manufacturing features any where in the large scale manufacturing process model without disrupting the every file and model. Moreover, global changes which affect the entire model may be made at the highest level via the first master process model e.g.,20a, reference set26 geometry, or virtual blank10 which then flow down to all the subsequent models by virtue of the associative relationships among them.

Turning now toFIG. 12, once again for insight into the utilization of a reference set26, the virtual blank10, and the multiple master process model(s)20a,20b, and20cwith their respective associated relationships and progeny are applied to facilitate a large-scale manufacturing process. In one or more sets of manufacturing process models, as disclosed in the abovementioned embodiments, one or more in process models or extract(s) may be generated from each of the master process model(s)20a,20b, and20crespectively (in this instance three are depicted). Once again, theextracts22 correspond to the state of the respectivemaster process models20a,20b, and20cat various operations for the virtual machining of the manufacturing features (e.g.,12a-12jof FIG.6). Referring also toFIGS. 6 and 8, it should also be apparent that in order to accomplish a large-scale manufacturing process, the virtual machining of manufacturing features12a-12j, the generation ofrespective extracts22, and the generation ofcorresponding process sheets23 is divided among the variousmaster process models20a,20b, and20c.

From the extract(s)22 associated with each master process model e.g.,20a,20b, and20c, corresponding process sheets may also be generated. Where again, extracts, of the respectivemaster process models20a,20b, and20care created at various operations of the manufacturing processes associated with a particular master process model of the plurality. Once again from theseextracts22, correspondingprocess sheets23 may be generated for specifying the manufacturing operations. Once again it should be recognized that theextracts22 andprocess sheets23 are created and include the characteristics, relationships and limitations as described above for horizontally structured models and horizontally structured process models. To avoid duplication, reference may be made to the abovementioned embodiments for insight concerning in process models or extracts and process sheets.

It is noteworthy to appreciate that the large-scale manufacturing operations process capability disclosed realizes its potential and significance primarily due to the characteristics of the horizontally structured model and manufacturing processes disclosed herein. Specifically, the separation/distribution of associative relationships in the models provides the enhancement achieved. In contrast, where the traditional approach to manufacturing modeling was to create separate individual models representing the real-world component at numerous particular operations in the manufacturing process. If a change or deletion was made in one model, it was necessary to individually update each of the other models having the same part. Using the horizontally structured modeling disclosed herein and employing the model link/unlink capabilities, it is now possible to generate multiple horizontally structured master process model(s) linked in a manner such that changes in one model are automatically carried out in other linked models enabling a multitude of alternate manufacturing processes. Further, thesubsequent process sheets23 that are linked thereto are also automatically updated. Any changes to a particularmaster process model20a,20b, or20care

automatically reflected in the correspondingextracts22 andprocess sheets23. Horizontally Structured Modeling Manufacturing Process

Modeling For Charted Parts

The model link/unlink functionality coupled with the horizontally structured process modeling as disclosed earlier brings forth new opportunities for enhancement of CAD/CAM modeling and manufacturing process modeling. One such opportunity is horizontally structured CAD/CAM modeling and manufacturing process modeling methods to facilitate charted parts manufacturing. Charted parts include, but are not limited to a group of machined parts exhibiting one or more common manufacturing features. For example, two independent machined parts that originate from the same casting. For a better understanding of the features of the disclosed embodiment, reference is made to the earlier disclosed horizontally structured modeling and horizontally structured manufacturing process modeling including model link/unlink disclosed above, and as further exemplified below.

In charted parts manufacturing processes, manufacturing models may need to be created for each individual part to be fabricated. Moreover, when a separate model is created for each manufacturing operation of a charted part where some elements of the model are common and yet no associative relationship exists between the manufacturing process models, a problem arises when one part or model requires an addition or modification. That being, that all subsequent models will also require manual updates to incorporate the desired modification. For example if a global change to a common casting was required.

Disclosed herein is an embodiment, which utilizes the features and characteristics of horizontally structured manufacturing process and the link/unlink functionality disclosed earlier to develop manufacturing process models that contain multiple parts that share common manufacturing features and element(s). In an exemplary embodiment, for all of the different parts, all common manufacturing features may be linked in associative relationships, while uncommon manufacturing features need not be associatively linked. Such a configuration coupled with the characteristics of the associative relationships between subsequent models, processes, or operations dictates that a change made in one is reflected down the entire stream.

The embodiment is described by way of illustration of descriptions of features in addition to the abovementioned embodiments, specifically, an enhancement to the horizontally structured manufacturing process modeling disclosed and claimed herein. Therefore, the disclosure will be in reference to and illustrated using manufacturing process modeling but is not to be construed as limited thereto.

Referring toFIG. 13, in the disclosed embodiment, horizontally structured modeling methods as disclosed above are employed to facilitate the generation of a manufacturing process for creating charted parts (e.g., a method for modeling and fabricating charted parts with some common and uncommon features). To facilitate the method disclosed, once again, the link/unlink and extraction functions disclosed above are here again employed.

To execute generating a manufacturing process for charted parts, multiple master process models are created each including features and manufacturing operations common to the required charted parts. The manufacturing process comprises a plurality of models each termed master process models analogous to those described above once again created or generated from a virtual blank10 extracted from the geometry of a reference set26 or a casting model. Initially amaster process model20 generated, which is virtual machined to include the manufacturing features common to all charted parts. Second, from thismaster process model20, one or more subsequent master process model(s)20dare created or generated and each of the part specific manufacturing features are added. In the figure, a single common master process model is depicted as well as a single master process model corresponding to a particular charted part. Subsequently additional master process models may be added for each additional charted part. In reference to the manufacturing process modeling, once again, master process models are created and include the characteristics, relationships and limitations as described above for horizontally structured models. To avoid duplication, reference may be made to the abovementioned embodiments for insight concerning a master process model and horizontally structured models.

In the figure, two such master process models are depicted. Themaster process model20 and the subsequentmaster process model20d. Once again, each of themaster process models20 and20dincludes associative relationships (e.g. links) as depicted by the arrows in the figure, with the virtual blank10 and subsequent corresponding in process models (extracts)22. Each associative relationship is characterized such that changes in the reference set26, virtual blank10, or particularmaster process model20 or subsequentmaster process model20dare reflected in all the subsequent linked in process models (extracts)22 corresponding to that particular master process model. Once again, themaster process models20 and20dmay be created in a variety of manners as described in the embodiments above. For example, in the Unigraphics® environment, themaster process model20 may be created or generated via virtual machining of a virtual blank10, which was created as a linked body or a promotion from a reference set26, as a replica of an existing model. A master process model may also be generated by the extraction process from an existing model element

“Extracts” of each master process model are utilized to generateprocess sheets23 or other instructions for each procedure to machine a real world part just as described in earlier embodiments. Thereby, the combination of the multiple processes enabling fabrication of charted parts may be created.

Turning now toFIG. 13 once again for insight into the utilization of a reference set26, virtual blank10, and themaster process model20, and subsequentmaster process model20dwith their respective associated relationships and progeny are applied to facilitate a manufacturing process for charted parts. Similar to the abovementioned embodiments, each of themaster process models20 and20dare configured to include associative relationships (e.g. links) configured such that changes in a reference set,26 or virtual blank10 are reflected in the subsequent linked master process models and their progeny. Likewise, as stated earlier, changes in the master process models e.g.,20 and20dwill not affect the parents.

An exemplary embodiment further illustrates application to a charted parts manufacturing process. Two master process models, e.g.,20 and20dare generated as disclosed herein, namely initiated with a virtual blank10 as a replica of the desired reference set26 or product casting. The virtual machining necessary to add all common desired manufacturing features, for example,12a,12b, and12c(FIG. 6) (12a-12jare depicted inFIG. 13) is performed on onemaster process model20 for example. Following the addition of the first subset of manufacturing features, a subsequent master process model e.g.,20dis generated. The manufacturing features from themaster process model20 are copied to the subsequentmaster process model20d. Thereby the common manufacturing features for example,12a,12b, and12care applied in the subsequentmaster process model20dwith modifiable constraints. The modifiable constraints enable the user to individually select and dictate the linkages and relationships among the various model elements. In this instance, for example this may include, but not be limited to, the linkages between the common manufacturing features (e.g.12a,12b, and12c) and the firstmaster process model20. Therefore the subsequentmaster process model20dmay include the common manufacturing features (e.g.12a,12b, and12c) and yet not necessarily include associative relationships with themaster process model20. The subsequent desired manufacturing features e.g.,12d, and12emay then be added to the subsequent master process model e.g.,20d. Moreover, the additional uncommon features may then be added to themaster process models20 and20d. Finally, as illustrated in the figure, as disclosed in the abovementioned embodiments, a plurality in process models or extract(s) may be generated from each of the master process model(s)20, and20drespectively (in this instance two are depicted). From the extract(s)22 associated with each master process model e.g.,20 and20dcorrespondingprocess sheets23 may also be generated. Where again, extracts, of the respectivemaster process models20 and20dare created at various operations of the manufacturing processes associated with a particular master process model of the plurality. Once again from theseextracts22, correspondingprocess sheets23 may be generated for specifying the manufacturing operations. Once again it should be recognized that theextracts22 andprocess sheets23 are created and includes the characteristics, relationships and limitations as described above for horizontally structured models and horizontally structured process models. To avoid duplication, reference may be made to the abovementioned embodiments for insight concerning in process models or extracts and process sheets.

A particular feature of the exemplary embodiment is that it would allow the user to readily add new manufacturing features and thus new charted parts any where in the charted parts manufacturing process model without disrupting the every file and model. Moreover, global changes, which affect the entire model may be made at the highest level via the master process model with the common features e.g., 20 or the referenced geometry, which then flow down to all the subsequent models by virtue of the associative relationships among them.

It is noteworthy to appreciate that the charted parts manufacturing operations process capability disclosed realizes its potential and significance primarily due to the characteristics of the horizontally structured model and manufacturing processes disclosed herein. Specifically, the separation/distribution of associative relationships in the models provides the enhancement achieved. In contrast, in “vertical” modeling and manufacturing processes, where the traditional approach to manufacturing modeling was to create separate individual models representing the real-world component at numerous particular operations in the manufacturing process. If a change or deletion was made in one model, it was necessary to individually update each of the other models having the same part. Using the horizontally structured modeling disclosed herein and employing the model link/unlink capabilities, it is now possible to generate multiple horizontally structured master process model(s) linked in a manner such that changes in one model are automatically carried out in other linked models enabling a multitude of charted parts manufacturing processes. Further, thesubsequent process sheets23 that are linked thereto are also automatically updated.

Virtual Concurrent Product and Process Design

Product and process modeling traditionally, involves the creation of two models, one to represent the finished component and another to represent the manufacturing processes. The two models generally include no feature linkages, particularly in the final product model and therefore, the models have to be manually updated to reflect any changes to the manufacturing process or the finished component. Moreover, certain operations may need to be repeated for both the product model and the manufacturing process modeling. Maintaining two models and manually updating models is cumbersome and expensive.

The model link/unlink functionality coupled with the horizontally structured process modeling as disclosed earlier brings forth new opportunities for enhancement of CAD/CAM modeling and manufacturing process modeling. One such opportunity is horizontally structured CAD/CAM modeling and manufacturing process modeling methods to facilitate concurrent product and process design. An exemplary embodiment addresses the deficiencies of known manufacturing modeling methods by creating a single master model to represent the finished component or product and the manufacturing process for the product.

For a better understanding of the features of the disclosed embodiment, reference is made to the earlier disclosed horizontally structured modeling and horizontally structured manufacturing process modeling including model link/unlink disclosed above, and as further exemplified below. The exemplary embodiment is described by illustration of additional features subsequent to the abovementioned embodiments, specifically an enhancement to the horizontally structured manufacturing process modeling disclosed and claimed herein. Therefore, the disclosure will be in reference to and illustrated using manufacturing process modeling as an example but is not to be construed as limited thereto.

In the disclosed method, horizontally structured modeling methods as disclosed above are employed to facilitate the generation of a product design and manufacturing process model for creating an actual part. The exemplary embodiment comprises a model termed master product and process concurrent model analogous to those described above, but including both the product design model and the manufacturing process model. In this instance, the master product and process concurrent model includes associative relationships (e.g. links) configured such that changes in master product and process model are reflected in all the subsequent linked in process models or extracts and subsequently process sheets. Similar to the above-mentioned embodiments, “extracts” of the master product and process concurrent model are utilized to generate process sheets or other instructions for each procedure to machine a real-world part.

Referring now toFIG. 14, to facilitate the disclosed embodiment, the link/unlink and extraction functions disclosed above may once again be employed. Moreover, to facilitate the disclosure reference should be made toFIGS. 6 and 8. To execute generating a combined product and manufacturing process model, once again in the same manner as described in the embodiments above, is a 3-D parametric solid model representative of the geometry of a reference set26 is created. The new model termed the master product and processconcurrent model40 includes, but is not limited to the combined elements, characteristics, and relationships of a virtual blank10 (e.g. FIG.5),datum planes2,3, and4 (e.g.FIG. 5) as in the horizontally structured modeling embodiment as well as a master process model20 (e.g.FIG. 5) as described in the horizontally structured manufacturing process modeling embodiments above. Moreover, the relationships, including, but not limited to, positional, orientational, associative, and the like, as well as combination of the foregoing among the model elements are also acquired and retained. To avoid duplication, reference may be made to the abovementioned embodiments for insight concerning a master process model and horizontally structured models.

Therefore, now the master product and processconcurrent model40 may be manipulated and modified as required to model the creation as well as the method of manufacturing the actual part. Once again, this master product and processconcurrent model40, logically, is a child of the reference set26 and virtual blank10. Moreover, once again, no mandatory associative relationship need exist among the master product and processconcurrent model40 and thedatum planes2,3, and4 (e.g.,FIG. 5) which comprise the reference 3-D coordinatesystem6 with respect to which, the manufacturing features12a-12j(FIG. 6) are positioned and oriented.

The described independence, as with the modeling described above provides significant flexibility in the product design modeling and manufacturing process modeling by allowing a user to interchangeably apply various features to a particular master product and processconcurrent model40. Likewise, interchangeable master product and processconcurrent models40 may be generated without impacting the particular manufacturing features12a-12jor datum planes (e.g.,2,3, and4) utilized. For example, different reference sets26 may be selected and a new master product and processconcurrent model40 generated therefrom and subsequently, the same manufacturing features12a-12jand associated datum planes (e.g.,2,3, and4) added.

Turning now toFIG. 14 once again for insight into the utilization of a reference set26, the virtual blank10, the master product and processconcurrent model40 with associated relationships and progeny are applied to facilitate a product design and manufacturing process. In an exemplary embodiment product models, as disclosed in the abovementioned embodiments may be generated, ultimately resulting in a product drawing44 depicting the design of the product. The product drawing including the information required to define the part, including, but not limited to, materials, characteristics, dimensions, requirements for the designed part or product, and the like, as well as combinations of the foregoing. In addition, from the master product and processconcurrent model40 one or more in-process models or extract(s) may be generated. From the extract(s)22 associated with the master product and processconcurrent model40, correspondingprocess sheets23 may thereafter be generated. Where again, extracts, of the master product and processconcurrent model40 are created at various operations of the manufacturing processes associated with a master product and processconcurrent model40. Once again from theseextracts22, correspondingprocess sheets23 may be generated for specifying the manufacturing operations. Once again it should be recognized that theextracts22 andprocess sheets23 are created and include the characteristics, relationships and limitations as described above for horizontally structured models and horizontally structured process models. To avoid duplication, reference may be made to the abovementioned embodiments for insight concerning in process models or extracts and process sheets.

In yet another exemplary embodiment of the concurrent product and process design modeling, the master product and processconcurrent model40 disclosed above may further be linked with a manufacturing process planning system. For example, the process planning system may be utilized to define the manufacturing in-process feature and manufacturing process parameters (e.g., machining speeds, material feed speeds, and the like, as well as combinations of the foregoing) based upon the finished product requirements. The process planning system may be developed within the CAD/CAM environment (e.g., Unigraphics® environment) or developed independently and linked with to the CAD/CAM system.

A process planning system is computer program to automate creation of manufacturing process plans based on existing manufacturing process knowledge, a rules database, and the like, including combinations of the foregoing. A process plan defines the sequence of operations and process parameters for manufacturing the component to meet the desired product geometry and quality requirements.

Preferably, the link between the process planning system and the master processconcurrent model40 may be achieved at the manufacturing feature (e.g.12a-12j) level. Thereby creating associative relationships among model elements and a process planning system and facilitating the planning process. For example, routines can be developed within the CAD/CAM system and the process planning system to share geometry and process data associated with the manufacturing features (e.g.,12a-12j). For example, process data may include, but not be limited to machining speeds, feeds, tooling, tolerances, manufacturing cost estimates, etc. Additionally, routines may be developed within a CAD/CAM system to enable creation and management of features within the master product and processconcurrent model40. The routines may thereafter be called by the process planning system to create and sequence manufacturing in-process features. Integration of a process planning system with the master product and processconcurrent model40 in such manner will enable rapid creation of process plans concurrent with the product designs.

It is noteworthy to appreciate that the concurrent product and process design modeling capability disclosed realizes its potential and significance primarily due to the characteristics of the horizontally structured modeling and manufacturing processes disclosed herein. Specifically, the separation/distribution of associative relationships in the models provides the enhancement achieved. In contrast, in “vertical” modeling and manufacturing processes, where the traditional approach to manufacturing modeling was to create separate models for product design and manufacturing process. If a change or deletion was made in one model, it was necessary to manually update the other model having the same part. Using the horizontally structured modeling disclosed herein and employing the model link/unlink capabilities, it is now possible to generate concurrent horizontally structured master product and process concurrent model linked in a manner such that changes are automatically carried out in both the product design and manufacturing models enabling significantly enhanced design and manufacturing processes. Further, thesubsequent process sheets23 that are linked thereto are also automatically updated. Any changes to a master product and processconcurrent model40 are automatically reflected in the correspondingextracts22 andprocess sheets23. Moreover, another aspect of the disclosed embodiment is the potential for integration of process planning and product/process design. Finally, the concurrent product and process design methods disclosed herein facilitate the utilization of a single file for both product and process design.

Virtual Fixture Tooling Process

Manufacturing tool and fixture drawings are often created and maintained as two-dimensional. This practice results in the manual editing of drawings. Moreover, such practice foregoes the generation of a three dimensional parametric solid model, which facilitates down stream applications. Significantly, manual editing eventually produces drawings, which may not be true to size. More damaging, is that many operators may avoid investing the time to incorporate the exact dimensional changes made to a part in the drawings, especially on two dimensional, tool, and fixture drawings.

A method is disclosed which automates the process of generating and editing contact tooling and fixture drawings. This new process creates a 3-D parametric solid model of contact tools and fixtures by linking the contact area of a tool and/or fixture to its corresponding final production part model or in process models. Thereby, contact area geometry exhibiting associative relationships with a modeled part will be automatically updated as the linked part is modified.

The model link/unlink functionality coupled with the horizontally structured process modeling as disclosed earlier brings forth new opportunities for enhancement of CAD/CAM modeling and manufacturing process modeling. One such opportunity is horizontally structured CAD/CAM modeling and manufacturing process modeling methods to facilitate virtual fixture and tooling product and process design. An exemplary embodiment addresses the deficiencies of known tooling and fixture design and modeling methods by creating linkages to a model, for example a casting model, and to the required in-process models for the finished component or product and the manufacturing process for the product.

For a better understanding of the features of the disclosed embodiment, reference is made to the earlier disclosed horizontally structured modeling and horizontally structured manufacturing process modeling including model link/unlink disclosed above, and as further exemplified below. The exemplary embodiment is described by illustration of additional features subsequent to the abovementioned embodiments, specifically an enhancement to the horizontally structured manufacturing process modeling disclosed and claimed herein. Therefore, the disclosure will be in reference to and illustrated using product CAD/CAM modeling and manufacturing process modeling as an example but is not to be construed as limited thereto.

In the disclosed embodiment, horizontally structured modeling methods as disclosed above are employed to facilitate the generation of a product design and manufacturing process model for creating an actual part and the tooling and fixtures there for. In an exemplary embodiment a model termed master process model analogous to those described above, and including similar characteristics is employed to generate tooling and fixture models, and fabrication instructions. In this instance, the master process model includes associative relationships (e.g. links) configured such that changes in master process model are reflected in all the subsequent linked in-process models or extracts and subsequently process sheets. Similar to the above-mentioned embodiments, “extracts” of the master product and process model are utilized to generate process sheets or other instructions for each procedure to machine a real-world part. Referring now toFIG. 15, as well asFIGS. 6 and 8 to facilitate the disclosed embodiment, the link/unlink and extraction functions disclosed and described above are once again employed. To execute generating a product and manufacturing process model configured to facilitate tooling and fixture generation, once again in the same manner as described in the embodiments above, a 3-D parametric solid model representative of the geometry of a reference set26 and virtual blank10 is generated or created. The new model, here again termed amaster process model20 includes, but is not limited to the elements, characteristics, and relationships of a reference set26 or casting as in the horizontally structured modeling embodiment. Moreover, the relationships among the model elements, including, but not limited to, positional, orientational, associative, and the like, as well as combination of the foregoing are also acquired and retained. To avoid duplication, reference may be made to the abovementioned embodiments for insight concerning amaster process model20 and horizontally structured models.

Therefore, now themaster process model20 may be manipulated and modified as required to model the creation as well as the method of manufacturing the actual part. Once again, thismaster process model20, logically, is a child of the reference set26. Moreover, once again, no mandatory associative relationship need exist among themaster process model20 and thedatum planes2,3, and4 (e.g., FIG.5). The datum planes2,3, and4 comprise the reference 3-D coordinatesystem6 with respect to which, the manufacturing features12a-12j(FIG. 6) are positioned and oriented.

The modeling characteristics described above, once again, provide significant flexibility in the product design modeling and manufacturing process modeling by allowing a user to interchangeably applyvarious manufacturing features12a-12jto a particularmaster process model20. Likewise, interchangeablemaster process models20 may be generated without impacting the particular manufacturing features (e.g. one or more of12a-12j) or datum planes (e.g.,2,3, and4) utilized. For example, different reference sets26 may be selected and a newmaster process model20 generated there from and subsequently, the same manufacturing features12a-12jand associated datum planes (e.g.,2,3, and4) added.

Turning once again toFIG. 15 for insight into the utilization of a reference set26, a virtual blank10, and themaster process model20 with associated relationships and progeny are applied to facilitate a product design, tooling and fixture design and fabrication, and a manufacturing process. Once again, as described earlier, from themaster process model20 one or more in-process models or extract(s) may be generated. From the extract(s)22 associated with themaster process model20, correspondingprocess sheets23 may thereafter be generated.

Where again, extracts22, of themaster process model20 are created at various operations of the manufacturing processes associated with amaster process model20 and the fabrication of the actual part. Once again from theseextracts22, correspondingprocess sheets23 may be generated for specifying the manufacturing operations. Once again it should be recognized that theextracts22 andprocess sheets23 are created and include the characteristics, relationships and limitations as described above for horizontally structured models and horizontally structured process models. To avoid duplication, reference may be made to the abovementioned disclosures for insight concerning in process models or extracts and process sheets.

Moreover, in an exemplary embodiment, as theextracts22 andprocess sheets23 are generated for the part under manufacture, selected two dimensional (2-D) contact area geometries and/or surfaces are established for tooling and fixtures to facilitate manufacturing. Associative relationships are established with such contact areas and surfaces. The selected contact area 2-D geometries are linked as described earlier, and established a new 2-D reference set. A new file is created, and the new 2-D reference set is imported to create the virtual tool or fixture. Similar to the abovementioned embodiments, in a Unigraphics® environment, a linked reference geometry is generated via the Wave link function from the new reference set. The linked 2-D reference geometry is then extruded to create a new 3-D parametric solid model for the virtual tool or fixture. This model may be termed atooling model25. The extrusion process is a method by which the linked 2-D reference geometry is expanded into a third dimension to 3-D parametric solid model. For example, a 2-D reference geometry of a circle may be extruded into a 3-D solid cylinder. The 3-D solid model now represents the contact tool and corresponds to the feature that is modeled or machined into the actual part. In an exemplary embodiment product models, termed atooling model25, may be generated. Thetooling model25 exhibits characteristics similar to those of other product models or master process models as disclosed in the above-mentioned embodiments. Thetooling model25 is utilized to ultimately generate a tool/fixture drawing46 depicting the design of the tool or fixture. The tool/fixture drawing46 includes the information required to define the tool/fixture, including, but not limited to, materials, characteristics, dimensions, requirements for the designed part or product, and the like, as well as combinations of the foregoing.

It is noteworthy to appreciate that the virtual tool and fixture design modeling capability disclosed herein realizes its potential and significance primarily due to the characteristics of the horizontally structured model and manufacturing processes disclosed herein and concurrent product and process design modeling. Specifically, the separation/distribution of associative relationships in the models provides the enhancement achieved. In contrast, in “vertical” modeling and manufacturing processes, where the traditional approach to manufacturing modeling was to create separate models for product design and manufacturing process and two-dimensional drawings for tooling/fixture design. If a change or deletion was made in one model, it was necessary to manually update the other model having the same part. Using the horizontally structured modeling disclosed herein and employing the model link/unlink capabilities, it is now possible to generate concurrent horizontally structured master process model linked in a manner such that changes are automatically carried out in both the product design manufacturing and tooling/fixture models enabling significantly enhanced design and manufacturing processes. Further, thesubsequent process sheets23, and tooling/fixture drawings46 that are linked thereto are automatically updated. Any changes to amaster process model20 are automatically reflected in the correspondingextracts22 andprocess sheets23.

Automated Manufacturing Process Design

The model link/unlink functionality coupled with the horizontally structured process modeling as disclosed earlier brings forth new opportunities for enhancement of CAD/CAM modeling and manufacturing process modeling. One such opportunity is horizontally structured CAD/CAM modeling and manufacturing process modeling methods to facilitate automated manufacturing process design. An exemplary embodiment addresses the deficiencies of known manufacturing process methods by creating a horizontally structured automated manufacturing process design including a master process model linked to a spread sheet to capture and organize manufacturing process rules.

Manufacturing process design involves the generation of rules and/or instructions for fabricating an actual part. The automation utilizes a spread sheet to capture the manufacturing process rules for particular parts. The manufacturing process rules may be organized by each manufacturing operation. Based on the process rules and the product dimensions, in-process dimensions may be calculated for manufacturing operations. Moreover, the spread sheets may also be linked with master process model such that changes incorporated into the spread sheets may be automatically reflected in the master process model, in-process models and associated process sheets and the like as well as combinations of the foregoing. Likewise, changes incorporated into the model elements such as master process model, in-process models and associated process sheets and the like as well as combinations of the foregoing may be automatically reflected in the spread sheets.

For a better understanding of the features of the disclosed embodiment, reference is made to the earlier disclosed horizontally structured modeling and horizontally structured manufacturing process modeling including model link/unlink functionality disclosed above, and as further exemplified below. The exemplary embodiment is described by illustration of additional features subsequent to the abovementioned embodiments, specifically an enhancement to the horizontally structured manufacturing process modeling disclosed and claimed herein. Therefore, the disclosure will be in reference to and illustrated using manufacturing process modeling as an example but is not to be construed as limited thereto.

In the disclosed embodiment, horizontally structured modeling methods as disclosed above are employed to facilitate the generation of an automated manufacturing process design model for creating an actual part. The exemplary embodiment comprises a model termed master process model analogous to those described above. In this instance, the master process model includes associative relationships (e.g. links) to a spread sheet including the manufacturing process rules. The master process model may be configured such that changes in master process model are reflected in all the subsequent linked spread sheets, in process models or extracts, subsequent process sheets and the like. Similar to the abovementioned embodiments, “extracts” of the master model are utilized to generate process sheets or other instructions for each procedure to machine a real-world part. Moreover, the master process model may be linked with numerically controlled (NC) tool paths and Coordinate Measuring Machine (CMM).

Referring now toFIG. 16, as wellFIGS. 6 and 8, to facilitate the disclosed embodiment, the link/unlink and extraction functions disclosed above are here again employed. To execute generating an automated manufacturing process design, once again in the same manner as described in the embodiments above, a 3-D parametric solid model representative of the geometry of a reference set26 is generated or created. The new model termed themaster process model20 includes, but is not limited to the combined elements, characteristics, and relationships of a reference set26 geometry and/or the virtual blank10 (e.g. FIG.8),datum planes2,3, and4 (e.g.FIG. 6) as in the horizontally structured modeling embodiment as well as a master process model20 (e.g.FIG. 8) as described in the horizontally structured manufacturing process modeling embodiments above. Moreover, the relationships, including, but not limited to, positional, orientational, associative, and the like, as well as combination of the foregoing among the model elements are also acquired and retained. To avoid duplication, reference may be made to the above-mentioned embodiments for insight concerning a master process model and horizontally structured models.

Therefore, now themaster process model20 may be manipulated and modified as required to model the creation as well as the method of manufacturing the actual part. Once again, thismaster process model20, logically, is a child of the reference set26 and virtual blank10. Moreover, once again, no mandatory associative relationship need exist among the master process model20 (e.g., in a Unigraphics® environment, the Wave linked geometry) and thedatum planes2,3, and4 (e.g.,FIG. 6) which comprise the reference 3-D coordinatesystem6 with respect to which, the manufacturing features12a-12jare positioned and oriented.

The described independence, as with the modeling described above provides significant flexibility in the product design modeling and manufacturing process modeling by allowing a user to interchangeably apply various features to a particularmaster process model20. Likewise, interchangeablemaster process models20 may be generated without impacting the particular manufacturing features (e.g., one or more of12a-12j) or datum planes (e.g.,2,3, and4) utilized. For example, different reference sets26 may be selected and a newmaster process model20 generated therefrom and subsequently, the same manufacturing features12a-12jand associated datum planes (e.g.,2,3, and4) added.

Turning now toFIGS. 16 and 17 as well as once again, referring toFIGS. 6 and 8, for insight into the utilization of a reference set26, the virtual blank10, themaster process model20 with associated relationships and progeny are applied to facilitate an automated product design and manufacturing process. In an exemplary embodiment manufacturing process models, as disclosed in the abovementioned embodiments may be generated, ultimately resulting inprocess sheets23 for manufacturing the product. The manufacturing process design involves the generation of rules and/or instructions for fabricating an actual part. The manufacturing rules may include, but not be limited to, manufacturing operation features, machining rules, speeds, feed rates, or tolerances, and the like as well as combinations of the foregoing. In an exemplary embodiment, the automation utilizes a spread sheet28 (FIGS. 16 and 17) to capture the manufacturing process rules for particular parts. The manufacturing process rules may be organized by each manufacturing operation. Based on the process rules and the product dimensions, in-process dimensions may be calculated for manufacturing operations. Moreover, thespread sheets28 may also be linked withmaster process model20 such that changes incorporated into thespread sheets28 may be automatically reflected in the master process model, in-process models or extracts22 and associatedprocess sheets23 and the like as well as combinations of the foregoing. Likewise, changes incorporated into the model elements such as virtual blank10,master process model20, manufacturing features, (e.g.,12a-12j;FIG. 6) extracts22, and associatedprocess sheets23 and the like as well as combinations of the foregoing may be automatically reflected in thespread sheets28.

In addition, from themaster product model20 one or more in-process models or extract(s) may be generated. From the extract(s)22 associated with themaster process model20, correspondingprocess sheets23 may thereafter be generated. Where again, extracts, of themaster process model20 are created at various operations of the manufacturing processes associated with amaster process model20. Once again from theseextracts22, correspondingprocess sheets23 may be generated for specifying the manufacturing operations. Once again it should be recognized that theextracts22 andprocess sheets23 are created and includes the characteristics, relationships and limitations as described above for horizontally structured models and horizontally structured process models. To avoid duplication, reference may be made to the abovementioned disclosures for insight concerning in process models or extracts and process sheets.

It is noteworthy to appreciate that the automated manufacturing process design modeling capability disclosed realizes its potential and significance primarily due to the characteristics of the horizontally structured model and manufacturing processes disclosed herein. Specifically, the separation/distribution of associative relationships in the models provides the enhancement achieved. In contrast, in “vertical” modeling and manufacturing processes, where the traditional approach to manufacturing modeling was to create separate models for product design and manufacturing process. If a change or deletion was made in one model, it was necessary to manually update the other model having the same part. Using the horizontally structured modeling disclosed herein and employing the model link/unlink capabilities, it is now possible to generate automated manufacturing processes employing horizontally structured master process model and a and a manufacturing rules spread sheet linked in a manner such that changes are automatically carried out in both the spread sheet and manufacturing models enabling significantly enhanced manufacturing processes. Further, thesubsequent process sheets23 that are linked thereto are also automatically updated. Any changes to amaster process model20 are automatically reflected in the correspondingextracts22 andprocess sheets23.

It should be noted the disclosed embodiments may be implemented on any CAD/CAM software system that supports the following functions and capabilities: reference planes, datum planes or similar Cartesian equivalents; parametric modeling, or similar equivalent; and feature modeling or similar equivalents.

It should be noted that the term modeling elements or elements of model and similar phraseology have been used throughout this specification. Such terminology is intended to include, but not be limited to: a reference, a reference axis, a reference datum, a datum, a coordinated system, a reference set, a geometry, a linked geometry, a linked body, a virtual blank, a base feature, a product model, a master process model, a master product and process concurrent model, an extract, an in-process model, an extracted body, a form feature, a manufacturing feature, a process sheet, a drawing, a product drawing, a tool drawing, a fixture, a spread sheet and the like as well as combinations of the foregoing.

It must be noted that the term “machining” has been used throughout this specification, but the teachings of the invention are applicable to any manufacturing process upon a blank, including welding, soldering, brazing & joining, deformations (e.g., crimping operations), stampings (e.g., hole punchings) and the like including combinations of the foregoing. For any of these manufacturing processes, the master process model can be used to represent the entire manufacturing process, from a blank to a finished component. Virtual in-process models (e.g., extracts) can then be created from the master process model to represent particular manufacturing processes.

The disclosed method may be embodied in the form of computer-implemented processes and apparatuses for practicing those processes. The method can also be embodied in the form of computer program code containing instructions embodied in tangible media, such as floppy diskettes, CD-ROMs, hard drives, or any other computer-readable storage medium, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes an apparatus capable of executing the method. The present method can also be embodied in the form of computer program code, for example, whether stored in a storage medium, loaded into and/or executed by a computer, or as data signal transmitted whether a modulated carrier wave or not, over some transmission medium, such as over electrical wiring or cabling, through fiber optics, or via electromagnetic radiation, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes an apparatus capable of executing the method. When implemented on a general-purpose microprocessor, the computer program code segments configure the microprocessor to create specific logic circuits.

While the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.

Claims (44)

1. A method of horizontally structured CAD/CAM manufacturing for fixtures and tooling, comprising:

selecting a contact area geometry for tooling or fixture modeling;

creating extracts from a master process model;.

generating a tooling model corresponding to said contact area geometry;

virtual machining said tooling model to generate said fixtures and tooling;

generating machining instructions and drawings to create said fixtures and tooling; and

said tooling model exhibiting an associative relationship with said contact area geometry.

2. The method ofclaim 1 wherein said contact area geometry corresponds to the dimensions of said tool or fixture.

3. The method ofclaim 1 wherein said contact area geometry is two-dimensional.

4. The method ofclaim 1 wherein said associative relationship is a parent/child relationship.

5. The method ofclaim 1 wherein said tooling model is a three dimensional parametric solid model generated by extruding a reference set geometry of said contact area geometry.

6. The method ofclaim 1 wherein said tooling model exhibits an associative relationship with said contact area geometry.

7. The method ofclaim 6 wherein said associative relationship is a parent/child relationship.

8. The method ofclaim 1 wherein said machining instructions and drawings exhibit an associative relationship with said tooling model.

9. The method ofclaim 8 wherein said associative relationship is a parent/child relationship.

10. The method ofclaim 1 wherein said extracts comprise replicated models of said tooling model at various operations of said manufacturing.

11. The method ofclaim 10 wherein said extracts are used to generate manufacturing process sheets.

12. A manufacturing part created by a method of horizontally structured CAD/CAM manufacturing for fixtures and tooling, comprising:

a contact area geometry selected from a master process model for tooling or fixture modeling;

extracts created from said master process model;

a tooling model corresponding to said contact area geometry including virtual machining said tooling model to generate said fixtures and tooling;

said fixtures and tooling created by machining in accordance with a machining instruction; and

said tooling model exhibiting an associative relationship with said contact area geometry.

13. The manufactured part ofclaim 12 wherein said contact area geometry corresponds to the dimensions of said tool or fixture.

14. The manufactured part ofclaim 12 wherein said contact area geometry is two-dimensional.

15. The manufactured part ofclaim 12 wherein said associative relationship is a parent/child relationship.

16. The manufactured part aclaim 12 wherein said tooling model is a three dimensional parametric solid model generated by extruding a reference set geometry of said contact area geometry.

17. The manufactured part orclaim 12 wherein said tooling model exhibits an associative relationship with said contact area geometry.

18. The manufactured part ofclaim 17 wherein said associative relationship is a parent/child relationship.

19. The manufactured part ofclaim 12 wherein said machining instructions and drawings exhibit an associative relationship with said tooling model.

20. The manufactured part aclaim 19 wherein said associative relationship is a parent/child relationship.

21. The manufactured part ofclaim 12 wherein said extracts comprise replicated models of said tooling model at various operations of said said manufacturing.

22. The manufactured part ofclaim 21 wherein said extracts are used to generate manufacturing process sheets.

23. A storage medium encoded with a machine-readable computer program code for horizontally structured CAD/CAM manufacturing for fixtures and tooling, said storage medium including instructions for causing a computer to implement a method comprising:

creating extracts from a master process model;

selecting a contact area geometry for tooling or fixture modeling;

generating a tooling model corresponding to said contact area geometry;

virtual machining said tooling model to generate said fixtures and tooling;

generating machining instructions and drawings to create said fixtures and tooling; and

said tooling model exhibiting an associative relationship with said contact area geometry.

24. The storage medium ofclaim 23 wherein said contact area geometry corresponds to the dimensions of said tool or fixture.

25. The storage medium ofclaim 23 wherein said contact area geometry is two-dimensional.

26. The storage medium ofclaim 23 wherein said associative relationship is a parent/child relationship.

27. The storage medium ofclaim 23 wherein said tooling model is a three dimensional parametric solid model generated by extruding a reference set geometry of said contact area geometry.

28. The storage medium ofclaim 23 wherein said tooling model exhibits an associative relationship with said contact area geometry.

29. The storage medium ofclaim 28 wherein said associative relationship is a parent/child relationship.

30. The storage medium ofclaim 23 wherein said machining instructions and drawings exhibit an associative relationship with said tooling model.

31. The storage medium ofclaim 30 wherein said associative relationship is a parent/child relationship.

32. The storage medium ofclaim 23 wherein said extracts comprise replicated models of said tooling model at various operations of said manufacturing.

33. The storage medium ofclaim 32 wherein said extracts are used to generate manufacturing process sheets.

34. A computer data signal for horizontally structured CAD/CAM manufacturing for fixtures and tooling, said computer data signal comprising code configured to cause a processor to implement a method comprising:

creating extracts from said master process model;

selecting a contact area geometry for tooling or fixture modeling;

generating a tooling model corresponding to said contact area geometry

virtual machining said tooling model to generate said fixtures and tooling;

generating machining instructions and drawings to create said fixtures and tooling; and

said tooling model exhibiting an associative relationship with said contact area geometry.

35. The computer data signal ofclaim 33 wherein said contact area geometry corresponds to the dimensions of said tool or fixture.

36. The computer data signal ofclaim 34 wherein said contact area geometry is two-dimensional.

37. The computer data signal ofclaim 34 wherein said associative relationship is a parent/child relationship.

38. The computer data signal ofclaim 34 wherein said tooling model is a three dimensional parametric solid model generated by extruding a reference ser geometry of said contact area geometry.

39. The computer data signal ofclaim 34 wherein said tooling model exhibits art associative relationship with said contact area geometry.

40. The computer data signal ofclaim 39 wherein said associative relationship is a parent/child relationship.

41. The computer data signal ofclaim 34 wherein said machining instructions and drawings exhibit an associative relationship with said tooling module.

42. The computer data signal ofclaim 41 wherein said associative relationship is a parent/child relationship.

43. The computer data signal ofclaim 34 wherein said extracts comprise replicated models of said tooling model at various operations of said manufacturing .

44. The computer data signal ofclaim 43 wherein said extracts are used to generate manufacturing process sheets.

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